Mounting bracket extension

ABSTRACT

An extension panel may include a mating surface shaped to interface with a back surface of a clamp that includes a mounting hole corresponding to a bolt slot in the back surface of the clamp to accommodate a single bolt passing through the extension panel and the clamp. The extension panel may also include a pair of flanges projecting outward from the mating surface and positioned to be on either side of the clamp. The extension panel may also include a flat top surface generally parallel and aligned linearly with another flat top surface of a flexible member. The extension flat top surface may be sized to be approximately a same width as the flexible member at a first end of the extension flat top surface proximate the mating surface and may flare out as the extension flat top surface extends away from the flexible member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.15/931,301, filed May 13, 2020, titled MOUNTING BRACKET EXTENSION, whichis incorporated herein by reference in its entirety.

THE FIELD OF THE DISCLOSURE

The present disclosure relates to a mounting bracket extension.

THE RELEVANT TECHNOLOGY

The present disclosure relates to mounting hardware for photovoltaicsystems.

Most photovoltaic (“PV”) modules are quite heavy because they use glassto encase the PV cells. A solar mounting system, therefore, must be ableto withstand the weight of an array of one or more PV modules and theforces of nature that may act upon it. In addition to supporting heavysolar arrays and the associated natural forces, solar tracking equipmentmust also be able to move the solar array so it tracks the sun. This canrequire motors with significant power. Therefore, mounting and trackingsystems for PV modules typically are relatively large, complexassemblies comprising large, heavy components.

These components can add significant cost to a solar power system for atleast two reasons. First, the components themselves are expensive tomanufacture, ship, and install. Second, installation and operation canbe expensive because they require time and skilled operators to conductquality control measures in the field. Therefore, there is a need for PVmounting system components that minimize the overall use of material tobe lighter weight and reduce costs. In addition, there is a need for PVmounting system components that can reduce the time necessary forinstallation and for quality control during construction in the field.

Furthermore, today a number of PV systems use modules that have customframes or unframed modules. Depending on whether the PV modules usestandard frames or these other variations, different components anddesigns are needed for the mounting and tracking systems. Thus, there isa need for a PV mounting system having a base design capable of mountingPV modules using standard frames, custom frames, and even unframedmodules.

Accordingly, there is a need for PV mounting system components thatefficiently use structural material only where it is needed. There isalso a need for a PV mounting system with components that provide easierand quicker installation and quality control capability. Finally, thereis a need for a PV mounting system capable of mounting modules usingstandard frames, custom frames, and even unframed modules.

The subject matter claimed herein is not limited to embodiments thatsolve any disadvantages or that operate only in environments such asthose described above. Rather, this section is only provided toillustrate one exemplary technology area where some embodimentsdescribed herein may be practiced

BRIEF SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential characteristics of the claimed subject matter, nor is itintended to be used as an aid in determining the scope of the claimedsubject matter.

One embodiment of the present disclosure includes a mounting bracketassembly that may include a flexible body. The flexible body may includea top member with a first flat top surface, and a flexible angled bottommember that may be connected to the top member and may define a beaminsertion aperture, where the flexible angled bottom member may includea first sloping surface along an outer edge of the bottom member. Themounting bracket assembly may also include a clamp that includes asecond sloping surface corresponding to and interfacing with the firstsloping surface, and a back surface on an opposite face from the firstsloping surface, where the back surface may be generally perpendicularto the first flat top surface when the second sloping surface interfaceswith the first sloping surface. The clamp may also include an armprojecting beyond the top member. The mounting bracket assembly mayadditionally include an extension panel, where the extension panel mayinclude a mating surface shaped to interface with the back surface ofthe clamp, and a second flat top surface generally parallel with andaligned linearly with the first flat top surface of the top member whenthe mating surface is interfaced with the back surface, where the secondflat top surface may extend away from the clamp at least half of alength of the first flat top surface. The mounting bracket assembly mayalso include a single bolt passing through the top member, the clamp,and the mating surface of the extension panel such that as the singlebolt is tightened, the clamp moves relative to the top member along aninterface between the first and second sloping surfaces while the firstflat top surface and the second flat top surface remain generallyaligned linearly.

Another embodiment of the present disclosure may include an extensionpanel that may include a mating surface shaped to interface with a backsurface of a clamp. The mating surface may include a mounting holecorresponding to a bolt slot in the back surface of the clamp and sizedto accommodate a single bolt passing through the extension panel and theclamp. The mating surface may also include a pair of flanges projectingoutward from the mating surface and positioned to be on either side ofthe clamp when the mating surface is interfaced with the back surface ofthe clamp. The extension panel may also include an extension flat topsurface generally parallel and aligned linearly, when the mating surfaceis interfaced with the back surface of the clamp, with a second flat topsurface of a flexible member. The flexible member may be positioned onan opposite side of the clamp from the extension panel. The extensionflat top surface may be sized to be approximately a same width as theflexible member at a first end of the extension flat top surfaceproximate the mating surface and may flare out as the extension flat topsurface extends away from the flexible member. The extension flat topsurface may include a plurality of mounting holes positioned to alignwith mounting features of a photovoltaic (PV) module.

An additional embodiment of the present disclosure may include a solarenergy gathering system. The solar energy gathering system may include asupport column, a torsion beam coupled to the support column andconfigured to be rotated, and a mounting bracket assembly. The mountingbracket assembly may include a flexible body that includes a top memberwith a first flat top surface, and a flexible angled bottom member thatmay be connected to the top member and may define a beam insertionaperture within which the torsion beam is disposed. The flexible angledbottom member may also include a first sloping surface along an outeredge of the flexible angled bottom member. The mounting bracket assemblymay additionally include a clamp that may include a second slopingsurface corresponding to and interfacing with the first sloping surface,and a back surface on an opposite face from the first sloping surface,where the back surface may be generally perpendicular to the first flattop surface when the second sloping surface interfaces with the firstsloping surface. The clamp may also include an arm projecting beyond thetop member. The mounting bracket assembly may additionally include anextension panel that may include a mating surface shaped to interfacewith the back surface of the clamp, and a second flat top surfacegenerally parallel with and aligned linearly with the first flat topsurface of the top member when the mating surface is interfaced with theback surface. The second flat top surface may extend away from the clampat least half of a length of the first flat top surface. The mountingbracket assembly may also include a single bolt passing through the topmember, the clamp, and the mating surface of the extension panel suchthat as the single bolt is tightened, the clamp moves relative to thetop member along an interface between the first and second slopingsurfaces. The solar energy gathering system may also include aphotovoltaic (PV) module fixedly mounted to the torsion beam via themounting bracket assembly. The PV module may be pinched between the armof the clamp and a combination of the first flat top surface of theflexible body and the second flat top surface of the extension panelsuch that as the torsion beam is rotated, an orientation of the PVmodule is changed.

Additional features and advantages of the disclosure will be set forthin the description which follows, and in part will be apparent from thedescription, or may be learned by the practice of the disclosure. Thefeatures and advantages of the disclosure may be realized and obtainedby means of the instruments and combinations particularly pointed out inthe appended claims. These and other features of the present disclosurewill become more fully apparent from the following description andappended claims, or may be learned by the practice of the disclosure asset forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other advantages and features of thepresent disclosure, a more particular description of the disclosure willbe rendered by reference to specific embodiments thereof which areillustrated in the appended drawings. It is appreciated that thesedrawings depict only typical embodiments of the disclosure and aretherefore not to be considered limiting of its scope. The disclosurewill be described and explained with additional specificity and detailthrough the use of the accompanying drawings in which:

FIG. 1 is a front perspective view of an example embodiment of amounting system and mounting bracket assembly in accordance with thepresent disclosure;

FIG. 2 is a front perspective view of an example embodiment of amounting system and mounting bracket assembly in accordance with thepresent disclosure;

FIG. 3 is a detail perspective view of an example embodiment of amounting system and mounting bracket assembly in accordance with thepresent disclosure;

FIG. 4A is a perspective view of an example embodiment of a mountingbracket assembly in accordance with the present disclosure;

FIG. 4B is a front view of the mounting bracket assembly of FIG. 4A;

FIG. 4C is a front cross-sectional view of the mounting bracket assemblyof FIG. 4A;

FIG. 5A is a perspective view of an example embodiment of a mountingbracket assembly in accordance with the present disclosure;

FIG. 5B is front view of the mounting bracket assembly of FIG. 5A;

FIG. 5C is a front cross-sectional view of the mounting bracket assemblyof FIG. 5A;

FIG. 6 is a detail perspective view of an example embodiment of amounting bracket assembly in accordance with the present disclosure;

FIG. 7 is an exploded view of an example embodiment of a mountingbracket assembly in accordance with the present disclosure;

FIGS. 8A-8D illustrate various views of an example embodiment of amounting bracket assembly and photovoltaic (PV) module, in accordancewith the present disclosure;

FIGS. 9A-9B illustrate various views of the mounting bracket assembly ofFIGS. 8A-8D;

FIG. 9C illustrates an exploded view of the mounting bracket assembly ofFIGS. 8A-8D;

FIGS. 10A and 10B illustrate various view of an example embodiment of anextension panel, in accordance with the present disclosure;

FIG. 11 illustrates an example of the mounting bracket assembly of FIGS.8A-8D and multiple PV modules, in accordance with the presentdisclosure; and

FIGS. 12A and 12B illustrate an example of the operation of the mountingbracket assembly of FIGS. 8A-8D when a bolt traversing the mountingbracket assembly is tightened.

DETAILED DESCRIPTION

The present disclosure relates to an improvement in mounting bracketassemblies through the use of extension panels. The extension panels maybe designed and shaped to extend the contact point and surface area overwhich a PV module is coupled to a mounting bracket assembly. However,rather than completely redesigning a new mounting bracket assembly toextend their reach and/or change the contact surface area, the presentdisclosure describes an extension panel that may be coupled with aseparate mounting bracket assembly to improve performance, speed,reliability, and durability of mounting bracket assemblies andinstallation thereof.

The brackets, assemblies, parts, and components disclosed herein may beused in connection with a variety of structures and devices, such asthose shown in U.S. Patent Publication No. 2017/0359017; 2018/0254740;and 2018/0348331; and U.S. Pat. Nos. 8,459,249; 9,281,778; 9,581,678;9,631,840; 10,042,030; and 10,069,455; each of which is incorporated byreference herein in its entirety.

In the following paragraphs, embodiments will be described in detail byway of example with reference to the accompanying drawings, which arenot drawn to scale, and the illustrated components are not necessarilydrawn proportionately to one another. Throughout this description, theembodiments and examples shown should be considered as exemplars, ratherthan as limitations of the present disclosure. As used herein, the“present disclosure” refers to any one of the embodiments describedherein, and any equivalents. Furthermore, reference to various aspectsof the disclosure throughout this document does not mean that allclaimed embodiments or methods must include the referenced aspects.

In general, embodiments of the present disclosure relate to mountingbracket assemblies, mounting assembly components, systems and associatedmethods. Example embodiments make efficient use of structural materialby using a flexible structural piece to secure an electricity generatingdevice. An electricity generating device could be any kind of devicethat directly or indirectly converts solar radiation to electricity orcollects, reflects, or concentrates solar radiation, includingphotovoltaic cells or modules, solar thermal devices, solar energycollectors, or components thereof. Disclosed assemblies and methodsprovide easier quality control capabilities. More particularly, rotatinga single clamping nut secures an electricity generating device such as aphotovoltaic (“PV”) module to a rounded, hexagonal, octagonal, etc.torsion beam. These and additional advantages are explained in moredetail below.

FIG. 1 illustrates an example solar mounting system, and FIGS. 2-12Billustrate various embodiments of and/or variations on the solarmounting system and/or components thereof. Certain components may be notillustrated in certain figures to facilitate an understanding of thecomponents that are shown, and their corresponding function.

FIGS. 1-3 illustrates an example solar mounting system 1, in accordancewith one or more embodiments of the present disclosure. The examplesolar mounting system 1 may include at least one support column 2, atorsion beam 3 connected to the support column 2 by a bearing 6, amounting rack (not shown) attached to the torsion beam 3, and at leastone photovoltaic (PV) module 5 mounted to the mounting system. Anexample mounting bracket assembly 10 may be used to mount the PV module5 to the torsion beam 3. The mounting bracket assembly 10 may includeextension panels, clamps, and/or a flexible body. The torsion beam 3 maybe any shape, including but not limited to, round, square, hexagonal,octagonal, or any hybrid shape such as rounded with flats on one or moresides. One of the advantages of the disclosed embodiments is the abilityof the mounting bracket to securely connect to a round or rounded tubeusing a single bolt, the threaded rod discussed herein. As discussed inmore detail herein, the mounting bracket assembly defines a beaminsertion aperture 28 (such as those illustrated in FIGS. 4A-5C) suchthat the torsion beam 3 may be disposed therein and run through theaperture.

An example mounting bracket assembly 10 comprises a body 12 orstructural piece that may be made in whole or in part of a flexible orsemi-flexible material. The flexible body 12 includes at least one topmember 14 and an angled bottom member 16 connected to the top member 14at opposite ends 18, 20 thereof. The top member 14 and/or bottom member16 may be made of a flexible or semi-flexible material. The angledbottom member 16 may be fixedly attached to the top member 14 or thebody 12 may be a unitary structure made by machining, extrusion,casting, molding, of cast aluminum, extruded aluminum, injection moldedplastic, or could be made of steel, fiberglass, composite, or any otherstrong flexible or semi-flexible material. The angle of the bottommember 16 may vary as seen in the embodiments of FIGS. 4A-4C and 5A-5C.A network of strengthening members 17 may be provided between the topmember 14 and the angled bottom member 16.

As illustrated in FIGS. 4A-7 , the body 12 includes a ring 44 thatdefines a beam insertion aperture 28 between the top member 14 and thebottom member 16. The beam insertion aperture 28 may be of any size orshape depending on the size and shape of the torsion beam 3 beinginserted therethrough, including but not limited to, round, square,hexagonal, octagonal, or any hybrid shape such as rounded with flats onone or more sides. The size of the ring 44 and the beam insertionaperture 28 may vary depending on the application, as seen in theembodiments of FIGS. 4A-4C and 5A-5C. The mounting bracket assembly 10is advantageously designed so it has structural material only wherenecessary and is in the shape and form of the stresses on the assembly.

In example embodiments, the body 12 of the mounting bracket assembly 10could have a two-piece construction, such as being joined by a slidablelocking mechanism, or as a hinged connection.

As illustrated in FIGS. 6 and 7 , at least one clamp 22 is attached toan end 18, 20 of the top member 14 and in example embodiments, a firstclamp 22 a is attached to a first end 18 of the top member 14 a and asecond clamp 22 b is attached to the second end 20 of the top member 14b. An example clamp 22 has an arm 24 and a flange 26. The arm 24 andflange 26 of the clamps 22 a, 22 b may serve to attach to the top orside of a frame 23 of a PV module 5 to hold the module in place. In someembodiments, the clamps 22 may secure the PV module by compression. Themounting bracket assembly 10 and clamps 22 may vary in length fordifferent module designs and load requirements.

Modifications, additions, or omissions may be made to FIGS. 1A-7 of thepresent disclosure. For example, changes as described herein may be madein accordance with the knowledge of a person of ordinary skill in theart. For example, the torsion beam may take any shape. As anotherexample, the body may take different forms, with different pitches onsloping surfaces, etc.

FIGS. 8A-12B illustrate various views of a mounting bracket assembly tofacilitate an understanding of one or more extension panels included aspart of the mounting bracket assembly. FIGS. 8A-8D illustrate variousviews of an example embodiment of a mounting bracket assembly 10 and PVmodule 5. FIGS. 9A-9B illustrate various views of the mounting bracketassembly of FIGS. 8A-8D, and FIG. 9C illustrates an exploded viewthereof. FIGS. 10A and 10B illustrate various views of an exampleembodiment of an extension panel. FIG. 11 illustrates an example of themounting bracket assembly of FIGS. 8A-8D and multiple PV modules. FIGS.12A and 12B illustrate an example of the operation of the mountingbracket assembly of FIGS. 8A-8D when the single bolt is tightened.Across each of FIGS. 8A-12B, similarly used numerals are used toidentify similar components.

As illustrated in FIGS. 8A-8D, the mounting bracket assembly 10 mayinclude the body 12, which may include one or more top members 14 (suchas the top members 14 a and/or 14 b), a bottom member 16, and a beaminsertion aperture 28 between the top members 14 and the bottom member16. The body 12 may also include one or more strengthening members 17.The mounting bracket assembly 10 may include one or more clamps 210(such as the clamps 210 a and/or 210 b) that may be similar orcomparable to the clamp 22 of FIGS. 2-7 , and may include an arm 214 anda flange 216. The clamp 22 may include a sloping surface 212 forinterfacing with a corresponding sloping surface 224 of the body 12.

As illustrated in FIGS. 8A-8D, the mounting bracket assembly 10 mayinclude one or more extension panels 250 (such as the extension panels250 a and 250 b). The extension panel 250 may be shaped and designed toprovide greater stability and support to the mounting bracket assembly10 when mounting the PV module 5 to the torsional beam 3. For example,the extension panel 250 may provide greater surface area between themounting bracket assembly 10 and a frame 23 of the PV module 5.Additionally or alternatively, the extension panels 250 may createcontact points further out along the length of the PV module 5 thanwould occur with the body 12 and the clamp 22 alone. By providing acontact point further away from the supporting structure (e.g., thetorsional beam 3), the PV module 5 may be permitted to be larger or workin environments which would otherwise be unsuitable for the PV module 5.For example, the use of the extension panels 250 may permit the use ofheavier PV modules 5 and/or longer/wider PV modules.

In some embodiments, the use of the extension panels 250 may mitigateundesirable forces acting on the PV module 5. For example, by extendingthe contact point further out along the length of the PV module 5, thetorsional forces experienced by the PV module 5 may be mitigated. Windforces may cause a twisting of the PV module 5 about the contact pointbetween the PV module 5 and the mounting bracket assembly 10. As thecontact point is extended further out along a length of the PV module 5,less of the PV module 5 experiences such torsional forces and suchforces may be reduced. This may be particularly advantageous as a sizeof the PV module 5 is extended. For example, the torsional forces for alarger surface-area PV module may be even more pronounced due to wind orother weather forces creating even greater forces while also extendingthe amount of the PV module that experiences the torsional forces. Incertain regions or areas with particularly strong winds, PV modules of acertain size may be unusable without the extension panels 250.Additionally, some PV modules may be so large as to be unusable withoutthe extension panels 250. As another example of the manner in which theextension panels 250 may mitigate undesirable forces acting on the PVmodule 5, the PV modules 5 are cantilevered from the contact point ofthe mounting bracket assembly 10 to the end of the PV module 5. Byextending the contact point further out along the PV module 5, less ofthe overall weight of the PV module 5 is cantilevered, placing lessmaterial stress on the PV module 5 and/or on the mounting bracketassembly 10.

As illustrated in FIGS. 8B-8D, in some embodiments, the mounting bracketassembly 10 may include an extension panel 250 on each end of themounting bracket assembly 10. For example, from left to right, themounting bracket assembly 10 may include a first extension panel 250 a,a first clamp 210 a, the body 12, a second clamp 210 b, and a secondextension panel 250, with the single bolt 270 passing through each ofthe first extension panel 250 a, the first clamp 210 a, the body 12, thesecond clamp 210 b, and the second extension panel 250.

The extension panel 250 may include a mating surface 252 to interfacewith a back surface 219 of the clamp 210. The mating surface 252 may begenerally perpendicular to the PV module 5. Alternatively, if the backsurface 219 of the clamp 210 is at an angle relative to the PV module 5rather than also being perpendicular to the PV module 5, the matingsurface 252 may be oriented and shaped to be flush with the back surface219 of the clamp 210 while a flat top surface 254 of the extension panel250 remains flush with the frame 23 of the PV module 5.

The mating surface 252 may include a bolt hole 255 through which asingle bolt 270 may pass. For example, the single bolt 270 may passthrough the body 12, the clamp 210, and the mating surface 252 of theextension panel 250. A head of the single bolt 270 and/or a nutassociated therewith may be disposed opposite where the mating surface252 interfaces with the back surface 219 of the clamp 210.

The flat top surface 254 may be positioned to be flush with the frame 23of the PV module 5. The flat top surface 254 may be approximately a samewidth as the body 12 on a first end proximate the mating surface 252 andmay flare out towards a second end distal from the mating surface 252.In some embodiments, for a portion of the flat top surface 254 at thedistal end, the flat top surface 254 may have a consistent width. At thedistal end, the flat top surface 254 may be approximately twice as wideas the frame 23 of the PV module 5 to accommodate two adjacent PVmodules 5. By providing the flat top surface 254 with a widthcorresponding to the width of the frames 23, the forces may be moreevenly distributed across a wider surface area of the extension panel250. In some embodiments, the distal end of the flat top surface 254 maybe wider than twice the width of the frame 23 or not as wide as twicethe width of the frame 23. The flat top surface 254 may be any length.For example, the flat top surface 254 may extend at least half thelength (e.g., the direction the single bolt 270 runs) of the body 12. Asanother example, the flat top surface 24 may extend at least as long asthe body 12.

In some embodiments, the flat top surface 254 may include one or moremounting holes 258. The mounting holes 258 may be size and positioned tocorrespond with mounting holes in the frame 23. The mounting holes 258may include one or more sets of mounting holes to accommodate varioussizes, dimensions, manufacturers, etc. of PV modules that may lead todifferent mounting configurations across different PV modules. Forexample, the mounting holes may accommodate 600, 800, and 990 mm holespacing along the frame 23. In some embodiments, the mounting holes 258may be symmetrically placed across the flat top surface 254 such thateach side of the extension panel 250 may be fixedly coupled to adistinct PV module such that a given extension panel may be coupled totwo separate PV modules adjacent to each other long the torsion beam 3.Doing so may facilitate alignment of the two PV modules 5 relative toeach other and may provide greater stability for the two PV modules whencoupled to the torsion beam 3 via the mounting bracket assembly 10. Insome embodiments, the mounting holes 258 may be shaped as slots suchthat a bolt within the mounting hole 258 may move laterally within theslot (e.g., in a same direction as the single bolt 270 runs) prior tobeing tightened against the frame 23 of the PV module 5. In someembodiments, the mounting holes 258 may be disposed in the region of aconsistent width at the distal end of the flat top surface 254.

In some embodiments, the extension panel 250 may include side panels 256extending down and away from the flat top surface 254. The side panels256 may provide greater structural integrity and support for the forcesexperienced by the extension panel 250. The side panels 256 may extenddownward a first depth proximate the mating surface 252. For example,the side panels may extend downward so that the side panels 256 extenddown the same distance as the mating surface 252. For a portion of theside panels 256, the side panels may slope back up towards the flat topsurface 254 from the proximate end of the extension panel 250 (e.g., theend proximate the mating surface 252) to the distal end (e.g., the endopposite the mating surface 252). In some embodiments, the portions ofthe side panels 256 that are sloping may correspond to the flaring widthof the flat top surface 254 such that as the flat top surface 254 getswider, the side panels 256 extend downward less, and when the flat topsurface 254 reaches a consistent width, the side panels 256 may remainat a consistent depth.

In some embodiments, the mating surface 254 may include one or moreflanges 253 projecting outwards and away from the mating surface 254.The flanges 253 may be positioned on either side of the clamp 210 suchthat as the single bolt 270 is tightened, the clamp 210 may remain inalignment with the extension panel 250. For example, the flanges 253 mayrestrict rotation of the clamp 210 to less than thirty degrees, lessthan twenty degrees, less than ten degrees, and/or less than fivedegrees from vertical in either direction.

As illustrated in FIG. 8A, as the single bolt 270 is tightened, theclamp 210 may move downward as the sloping surface 212 of the clamp 210slides along the sloping surface 224 of the body 12. As the clamp 210moves, the top member 14 and the flat top surface 254 of the extensionpanel 250 may remain flush with the frame 23 of the PV module 5. Theclamp 210 may pinch the frame 23 between the flange 216 of the clamp 210and a combination of the top member 14 and the extension panel 250. Thecompressive force between the flange 216 and the top member 14 and theextension panel 250 may maintain the PV module 5 in place. Additionallyor alternatively, the PV module 5 may be bolted to the extension panel250.

FIGS. 9A-9C illustrate the mounting bracket assembly of FIGS. 8A-8Dwithout illustrating the PV module 5 and the frame 23.

As illustrated in FIG. 9A, in some embodiment, the extension panel 250may include a slot 257 and/or a tab 259. In these and other embodiments,the flanges 253 may be an extension of the side panels 256 around anedge and to a same side as the mating surface 252. The side panels 256may include a gap in material for the slot 257 through which the tab 259may project. For example, the tab 259 may be an extension of the matingsurface 252. The tab 259 and slot 257 may provide additional structuralsupport and rigidity for the extension panel 250. Additionally oralternatively, the slot 257 and the tab 259 may facilitate manufacturingthe extension panel 250. For example, when forming the extension panel250 the component may begin as a flat piece of material and portions maybe bent or otherwise manipulated to form the mating surface 252,followed by the side panels 256 and the flanges 253. When performing thebending and/or other manipulation, the slot 257 and the tab 259 mayfunction as stops to limit and control how far the portions are bentsuch that the extension panel 250 remains in the desired shape andorientation.

FIG. 9C illustrates an exploded view of the mounting bracket assembly10. As illustrated from left to right, the mounting bracket assembly 10may include the first extension panel 250 a, which may interface withthe first clamp 210 a. The first clamp 210 a may include a slot for thesingle bolt 270 such that the clamp 210 a may change position whilestill having the single bolt 270 pass therethrough. The flanges 253 mayproject along either side of the clamp 210 a. The clamp 210 a mayinterface with the body 12. The body 12 may additionally interface withthe clamp 210 b. The clamp 210 b may interface with the second extensionpanel 250 b. The single bolt 270 may pass through the bolt hole 255 ofthe second extension panel, through a slot for the bolt in the secondclamp 210 b, through mounting holes between the top members 14 and thebottom member 16 of the body 12, through a slot for the bolt in thefirst clamp 210 a, and through the bolt hole 255 of the first extensionpanel 250. The single bolt 270 may include a head, washers, and or nutsat either or both ends of the single bolt 270. A visualization oftightening the single bolt 270 is illustrated in FIGS. 12A and 12B.

FIGS. 10A and 10B illustrate the extension panel 250 without othercomponents for ease in visualizing the extension panel 250.

As illustrated in FIGS. 10A/10B, in some embodiments, the bolt hole 255may be square or any other shape to accommodate the single bolt 270. Insome embodiments, the bolt hole 255 may be sized to limit movement ofthe extension panel 250 relative to the single bolt 270. For example,the bolt hole 255 may include, at its narrowest point around the singlebolt 270, clearance of between 1 mm and 5 mm in each direction, between0 and 10 mm, or any other range or size.

In some embodiments, the side panels 256 may include a sloping portion262 and a consistent portion 263. The sloping portion 262 may start at afirst depth that is approximately the same as that of the mating surface252. As the sloping portion 262 progresses away from the mating surfaceand towards the mounting holes 258, the size of the side panels 256 maydecrease. In some embodiments the consistent portion 263 may correspondto the portion of the extension panel 250 in which the flat top surface254 is a consistent width. In some embodiments, the side panels 256 mayextend all the way around the extension panel 250, such that the matingsurface 252 may be part of the side panels 256. In some embodiments, theside panels 256 may extend for a portion of the way around the extensionpanel 250. For example a rear edge 264 may include a gap or void in theside panels 256 that may cover a portion of a side, an entire side, ormore. By providing the void in the side panels 256 at the rear edge 264,it may be easier to reach the single bolt 270 with tools.

FIG. 11 illustrates an embodiment in which the mounting bracket assembly10 is mounting two PV modules 5 (including the PV modules 5 a and 5 b)to the torsion beam 3. In these and other embodiments, the extensionpanels 250 a/b are observed to be approximately the same width as theframes 23 a/23 b. Additionally, the extension panels 250 a/b mayfacilitate orientation and support of both PV modules 5 a/5 b.

FIGS. 12A and 12B illustrate an embodiment in which the single bolt 270is tightened from one view in FIG. 12A to the next view in FIG. 12B.

As illustrated in FIG. 12A, the single bolt 270 may pass through theextension panel 250, the clamp 210, and the body 12. Additionally oralternatively, a bolt 275 may pass through a hole in the frame 23 andthe mounting hole 258 of the extension panel 250 where the mounting hole258 may be a slot.

As illustrated in FIG. 12B, as the single bolt 270 is tightened,multiple components within the mounting bracket assembly 10 may beadjusted relative to each other. As the single bolt 270 is tightened,the clamp 210 is forced downward along the interface between the slopingsurfaces 224 and 212. As the clamp 210 moves downward, the single bolt270 moves from a position at a bottom of a slot 218 within the clamp 210towards a position at a top of the slot 218. By using the slot 218, theclamp 210 is able to move relative to the body 12 and the extensionpanel 250 while still having the single bolt 270 threaded therethrough.As the clamp 210 moves downwards, the clamp 210 pinches the frame 23between the clamp and a combination of the top member 14 and the flattop surface 254 of the extension panel 250.

Additionally, as the single bolt 270 is tightened, the two sides of thebody 12 are tightened around the torsion beam 3 such that the mountingbracket assembly 10 becomes fixedly coupled to the torsion beam 3. Bydoing so, the PV module 5 may be mounted to the mounting bracketassembly 10 and thereby coupled to the torsion beam 3.

As the single bolt 270 is tightened, the extension panel 250 is alsodrawn in towards a center of the mounting bracket assembly 10. As theextension panel 250 is drawn in, the bolt 275 placed through themounting hole 258 (implemented as a slot) and the frame 23 may bepermitted to slide within the slot of the mounting hole 258. By doingso, the bolt 275 may be placed within the mounting hole 258 even beforetightening the single bolt 270 to help with alignment of the PV module 5while tightening the single bolt 270.

In some embodiments, in installing an energy capturing system with a setof PV modules 5 to be installed on a torsion beam 3, a first mountingbracket assembly 10 may be disposed upon the torsion beam 3 and a PVmodule 5 may be positioned underneath the clamp 210 and resting on thetop member 14 and the extension panel 250. The bolt 275 may be placedthrough the frame 23 of the PV module 5 and the mounting hole 258 of theextension panel 250. The single bolt 270 may then be tightened, therebyclamping the PV module to the top member 14 and the extension panel 250while also tightening the body 12 about the torsion beam 3 by tighteningthe body 12 around the torsion beam 3. After the single bolt 270 hasbeen sufficiently tightened to secure the PV module 5 to the mountingbracket assembly 10 and the mounting bracket assembly 10 to the torsionbeam 3, the bolt 275 may be tightened to further secure the PV module 5to the mounting bracket assembly 10.

A second mounting bracket assembly 10 may then be positioned on theopposite side of the first PV module 5 along the torsion beam 3 suchthat the first PV module 5 is underneath the clamp 210 of the secondmounting bracket assembly 10 and a second PV module 5 may be disposedadjacent the first PV module 5 such that the second PV module 5 isbeneath the clamp 210 of the second mounting bracket assembly 10 andresting on the top member 14 and the extension panel 250 of the secondmounting bracket assembly 10. Bolts 275 may be placed through the frames23 of both the first and second PV modules 5 and the mounting holes 258on both sides of the second extension panel 250. The single bolt 270 ofthe second extension panel 250 may then be tightened, thereby securingand clamping down the frames 23 of both the first and the second PVmodules 5 against a combination of the top members 14 and the flat topsurfaces 254 of the extension panels 250 of the second mounting bracketassembly 10. After securing both PV modules, the bolts 275 may besecured for both PV modules 5. The process may be repeated for anynumber of PV modules 5 and/or mounting bracket assemblies 10 along thetorsion beam 3.

Modifications, additions or omissions may be made to the mountingbracket assembly of FIGS. 8A-12B without departing from the scope of thepresent disclosure. For example, while bolts are described, any type ofphysically coupling mechanism or device may be used. As another example,any profile or size of extension panel may be used. For example, shorterextension panels may be used for smaller PV modules and larger/longerextension panels may be used for larger PV modules.

While the present disclosure has used an example mounting bracketassembly using a single bolt to tighten the mounting bracket assembly tothe torsion beam and tighten the PV modules to the mounting bracketassembly, the use of an extension panel in accordance with the presentdisclosure is applicable to any other mounting bracket assembly. Forexample, any style or form of mounting bracket assembly that may be usedto couple to a torsion beam may have extension panels attached thereto,consistent with the present disclosure. Attaching such extension panelsto any style of mounting bracket assembly may permit such a mountingbracket assembly to enjoy the benefits described in the presentdisclosure, such as increased strength, improved distribution of forces,increased wind resistance, etc. For example, a mounting bracket assemblymay include a flat piece of metal to which PV module(s) may be attached(e.g., bolted), and U-bolt extending from the flat piece of metal,around the torsion beam, and back up to the flat piece of metal and maycouple the flat piece of metal to the PV torsion beam. Such a mountingbracket assembly may include extension panels coupled to the flat pieceof metal, in accordance with the present disclosure. Any other style,form, or type of mounting bracket assembly coupled with extension panelsin any form are also contemplated as consistent with the presentdisclosure.

The various features illustrated in the drawings may be, but are notnecessarily, drawn to scale. The illustrations presented in the presentdisclosure are not meant to be actual views of any particular apparatus(e.g., device, system, etc.) or method, but are merely idealizedrepresentations that are employed to describe various embodiments of thedisclosure. Accordingly, the dimensions of the various features may bearbitrarily expanded or reduced for clarity. In addition, some of thedrawings may be simplified for clarity. Thus, the drawings may notdepict all of the components of a given apparatus (e.g., device) or alloperations of a particular method.

Terms used in the present disclosure and especially in the appendedclaims (e.g., bodies of the appended claims) are generally intended as“open” terms (e.g., the term “including” should be interpreted as“including, but not limited to,” the term “having” should be interpretedas “having at least,” the term “includes” should be interpreted as“includes, but is not limited to,” among others).

Relative terms used in the present disclosure and especially in theappended claims (e.g., bodies of the appended claims) are generallyintended as falling within manufacturing tolerances and/or within scopereasonably understood by a person of skill in the art. For example, iftwo components are identified as being the “same” size, there may bevariations consistent with manufacturing variances. Terms describing“approximately,” “similar,” “substantially,” or other terms designatingsimilarity may convey within ten percent of the comparative value. Forexample, two components that are approximately the same size would beunderstood to be of a size within ten percent of each other.

Additionally, if a specific number of an introduced claim recitation isintended, such an intent will be explicitly recited in the claim, and inthe absence of such recitation no such intent is present. For example,as an aid to understanding, the following appended claims may containusage of the introductory phrases “at least one” and “one or more” tointroduce claim recitations.

In addition, even if a specific number of an introduced claim recitationis explicitly recited, those skilled in the art will recognize that suchrecitation should be interpreted to mean at least the recited number(e.g., the bare recitation of “two recitations,” without othermodifiers, means at least two recitations, or two or more recitations).Furthermore, in those instances where a convention analogous to “atleast one of A, B, and C, etc.” or “one or more of A, B, and C, etc.” isused, in general such a construction is intended to include A alone, Balone, C alone, A and B together, A and C together, B and C together, orA, B, and C together, etc.

Further, any disjunctive word or phrase presenting two or morealternative terms, whether in the description, claims, or drawings,should be understood to contemplate the possibilities of including oneof the terms, either of the terms, or both terms. For example, thephrase “A or B” should be understood to include the possibilities of “A”or “B” or “A and B.”

However, the use of such phrases should not be construed to imply thatthe introduction of a claim recitation by the indefinite articles “a” or“an” limits any particular claim containing such introduced claimrecitation to embodiments containing only one such recitation, even whenthe same claim includes the introductory phrases “one or more” or “atleast one” and indefinite articles such as “a” or “an” (e.g., “a” and/or“an” should be interpreted to mean “at least one” or “one or more”); thesame holds true for the use of definite articles used to introduce claimrecitations.

Additionally, the use of the terms “first,” “second,” “third,” etc., arenot necessarily used herein to connote a specific order or number ofelements. Generally, the terms “first,” “second,” “third,” etc., areused to distinguish between different elements as generic identifiers.Absence a showing that the terms “first,” “second,” “third,” etc.,connote a specific order, these terms should not be understood toconnote a specific order. Furthermore, absence a showing that the terms“first,” “second,” “third,” etc., connote a specific number of elements,these terms should not be understood to connote a specific number ofelements. For example, a first widget may be described as having a firstside and a second widget may be described as having a second side. Theuse of the term “second side” with respect to the second widget may beto distinguish such side of the second widget from the “first side” ofthe first widget and not to connote that the second widget has twosides.

All examples and conditional language recited in the present disclosureare intended for pedagogical objects to aid the reader in understandingthe invention and the concepts contributed by the inventor to furtheringthe art, and are to be construed as being without limitation to suchspecifically recited examples and conditions. Although embodiments ofthe present disclosure have been described in detail, it should beunderstood that the various changes, substitutions, and alterationscould be made hereto without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. An extension panel, comprising: a mating surfaceshaped to interface with a back surface of a clamp, the mating surfacecomprising: a mounting hole corresponding to a bolt slot in the backsurface of the clamp and sized to accommodate a single bolt passingthrough the extension panel and the clamp; and a pair of flangesprojecting outward from the mating surface and positioned to be oneither side of the clamp when the mating surface is interfaced with theback surface of the clamp; and an extension flat top surface generallyparallel and aligned linearly, when the mating surface is interfacedwith the back surface of the clamp, with a flexible member flat topsurface of a flexible member, the flexible member positioned on anopposite side of the clamp from the extension panel, the extension flattop surface sized to be approximately a same width as the flexiblemember at a first end of the extension flat top surface proximate themating surface and flaring out as the extension flat top surface extendsaway from the flexible member, the extension flat top surface includinga plurality of mounting holes positioned to align with mounting featuresof a photovoltaic (PV) module.
 2. The extension panel of claim 1,wherein the flanges prevent rotational movement of the clamp relative tothe extension panel beyond twenty degrees in either direction.
 3. Theextension panel of claim 1, wherein the extension flat top surfacefurther comprises side panels extending a first depth away from theextension flat top surface at a first position proximate the matingsurface and slope to a second depth more shallow than the first depth ata second position further away from the mating surface than the firstposition.